Melt-bondable panel mounting brackets, systems, and methods

ABSTRACT

Panel mounting components and systems for mounting objects, such as decorative architectural resin panels, can include a melt-bondable panel mounting bracket. Melt-bondable panel mounting brackets can include one or more bonding features configured to be pressed or rotated into a resin-based panel, thereby allowing additional components, such as a twist-lock mounting assembly, to be secured directly to a single side of a panel. Methods of securing melt-bondable panel mounting brackets to a resin panel can include rotating the melt-bondable panel mounting brackets at high speeds of rotation to cause a portion of the resin panel to melt and bond about the melt-bondable panel mounting brackets.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present invention in a continuation-in-part of PCT Application No.US09/64107, filed Nov. 12, 2009, entitled “Panel Mounting Components,Systems, and Methods,” which claims the benefit of priority to U.S.Provisional Application No. 61/114,521, filed Nov. 14, 2008, entitled“Melt-Bondable Panel Mounting Brackets and Methods,” and U.S.Provisional Application No. 61/155,310, filed Feb. 25, 2009, entitled“Click-lock Panel Mounting Apparatus, Systems, and Methods.” The entirecontents of above-referenced applications are incorporated by referenceherein.

BACKGROUND OF THE INVENTION

1. The Field of the Invention

The present invention relates to systems, methods, and apparatus formounting and/or displaying panels as partitions, displays, barriers,treatments, or other structure.

2. Background and Relevant Art

Recent trends in building design involve adding to or changing thefunctional and/or aesthetic characteristics of a given structure ordesign space by mounting one or more decorative panels thereto. This isat least partly since there is sometimes more flexibility with how thepanel (or set of panels) is designed, compared with the originalstructure. Panels formed from resin materials are particularly popularbecause they tend to be less expensive, in most applications, thanmaterials such as glass or the like, where certain structural, optical,and aesthetic characteristics are desired. In addition, resin materialstend to be more flexible in terms of manufacture and assembly becausethey can be relatively easily bent, molded, colored, shaped, cut, andotherwise modified in a variety of different ways. Decorative resins canalso provide more flexibility compared with glass and other conventionalmaterials at least in terms of color, degree of texture, gauge, andimpact resistance. Additionally, decorative resins have a fairly wideutility since they may be formed to include a large variety of colors,images, interlayers, and shapes.

Unfortunately, conventional hardware used to mount such panels tends tosuffer from a number of drawbacks. For example, mounting panels to awall or other support structure using such conventional hardware can bedifficult and labor intensive. For example, one conventional type ofmounting system used to secure panels to a support structure (e.g.,wall, ceiling, or frame) uses one or more standoffs. In general, astandoff positions a panel at a “standoff” (or extended) position withrespect to the support structure. In particular, after mounting astandoff to a support structure, an assembler is typically required tohold the panel in a desired mounting position, attempt to align aperforation in the panel with the standoff, align and thread a screwthrough the perforation in the panel, and secure the screw to thestandoff

One will appreciate that this and similar mounting processes can bedifficult and cumbersome, particularly when using large or heavy panels.Indeed, due to the awkwardness that may be caused by conventionalmounting hardware, installers can easily drop or otherwise damage panelsduring installation. Additionally, because conventional panel mountingsystems require complicated hardware and installation processes theytypically do not allow panels to be easily or quickly assembled anddisassembled. This can be problematic since a user may need to regularlyremove panels to access the space beyond the panels for the changing oflighting bulbs, HVAC maintenance, etc.

Furthermore, when mounting panels to support structures usingconventional standoffs, individual standoffs are often secured to thecorners or edges of the panel one at a time. One will appreciate thatthis means a panel may be supported by only one or two standoffs duringthe installation process. This unbalanced support can cause increasedconcentration of stresses in the panel around these standoffs, whichoften leads to cracks and other panel damage. Additionally, when onlyone or two standoffs are secured to a panel it is easy for an installerto inadvertently bend the panel about such standoffs in an attempt toalign further standoffs, which can cause panel damage.

The mounting of decorative panels using conventional hardware typicallyrequires tools that may lead to panel damage. For example, conventionalpanel mounting hardware, such as standoffs, typically requires the useof a wrench or screw driver in close proximately to a panel forassembly. Wrenches and other large tools are often cumbersome to use andmay lead to inadvertent panel damage. For instance, assemblers oftenscratch or otherwise damage panels during tightening of the hardware.

In addition to the foregoing, conventional mounting hardware is oftenunsightly, too noticeable, or does not provide an appropriate aestheticfor desired design environments. The unpleasant aesthetic ofconventional mounting hardware is often magnified when used withtranslucent, transparent, or other panels that magnify texture, light,color, and form. For example, the caps of conventional standoffs oftencover at least a portion of the display surface of the panel and mayotherwise detract from the aesthetics provided by the panel. Thus,conventional mounting hardware may be unappealing to designers andarchitects seeking to obtain a certain aesthetic by using decorativearchitectural panels.

In particular, this undesired aesthetic is often a result of mountinghardware, such as a conventional standoff cap, protruding from the panelsurface. In addition to providing an undesirable aesthetic, protrudingstandoff caps can also present various functional drawbacks. Forinstance, conventional, protruding standoffs typically do not allow fora panel to be mounted as a wall, countertop, or step with asubstantially smooth or flush surface. Furthermore, a protrudingstandoff cap may reduce the usable surface area of the panel, and createa protruding structure upon which objects (such as loosing clothingetc.) can easily catch or hook.

Accordingly, there are a number of disadvantages in conventional panelmounting systems and hardware that can be addressed.

BRIEF SUMMARY OF THE INVENTION

Implementations of the present invention solve one or more of theforegoing problems in the art with systems, methods, and apparatus formounting panels as partitions, displays, barriers, treatments, or otherstructure with increased functional versatility. In particular, variouscomponents, systems, and methods described herein allow panels to bequickly and efficiently assembled and disassembled with relative ease.For example, one or more other implementations can include amelt-bondable panel mounting bracket for mounting an object, such as adecorative architectural resin-based, to a support structure. Such canprovide a secure and reliable way to mount panels that alsosignificantly reduces the time and labor needed to mount and/or dismountpanels to a structure.

For example, an implementation of a melt-bondable panel mounting bracketcan include a body. The melt-bondable panel mounting bracket can alsoinclude one or more bonding protrusions extending a first distance in adirection generally away from the body. Furthermore, the melt-bondablepanel mounting bracket can include one or more ridges extendingtransversely from the one or more bonding protrusions. Additionally, themelt-bondable panel mounting bracket can include an alignment stemextending a second distance in a direction generally away from the body,the second distance being greater than the first distance.

An implementation of a system for securing a melt-bondable panelmounting bracket into a resin panel can include a drill interfaceconfigured to couple a melt-bondable panel mounting bracket to arotation tool. The system can also include a fender coupled to the drillinterface. Additionally, the system can include a stop guide configuredto receive the melt-bondable panel mounting bracket therein. The stopguide can prevent advancement of the melt-bondable mounting bracket andthe fender relative to the stop guide after the melt-bondable mountingbracket has been advanced a predetermined distance into the resin panel.

In addition to the foregoing, an implementation of a method of mountinga panel to a support structure can involve drilling a guide hole atleast partially through a resin panel. The method can also involveinserting an alignment stem of a melt bondable mounting panel bracketinto the guide hole. Additionally, the method can involve rotating themelt-bondable panel mounting bracket at a high rate of rotation, therebycausing resin of the resin panel to melt about one or more ridges of themelt-bondable panel mounting bracket, and thereby creating a bondbetween the melt-bondable panel mounting bracket and the resin panel.Furthermore, the method can involve advancing the melt-bondable mountingbracket into the resin panel.

Additional features and advantages of exemplary implementations of thepresent invention will be set forth in the description which follows,and in part will be obvious from the description, or may be learned bythe practice of such exemplary implementations. The features andadvantages of such implementations may be realized and obtained by meansof the instruments and combinations particularly pointed out in theappended claims. These and other features will become more fullyapparent from the following description and appended claims, or may belearned by the practice of such exemplary implementations as set forthhereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to describe the manner in which the above-recited and otheradvantages and features of the invention can be obtained, a moreparticular description of the invention briefly described above will berendered by reference to specific embodiments thereof which areillustrated in the appended drawings. It should be noted that thefigures are not drawn to scale, and that elements of similar structureor function are generally represented by like reference numerals forillustrative purposes throughout the figures. Understanding that thesedrawings depict only typical embodiments of the invention and are nottherefore to be considered to be limiting of its scope, the inventionwill be described and explained with additional specificity and detailthrough the use of the accompanying drawings in which:

FIG. 1 illustrates an elevated perspective-view of a twist-lock mountingassembly secured to a panel via a melt-bondable panel mounting bracketin accordance with an implementation of the present invention;

FIG. 2 illustrates an exploded side-view of the twist-lock mountingassembly of FIG. 1;

FIG. 3 illustrates a top view into the housing of the twist-lockmounting assembly of FIG. 1;

FIG. 4A illustrates a side view of a locking pin being inserted into thehousing of the twist-lock mounting assembly of FIG. 2 in accordance withan implementation of the present invention;

FIG. 4B illustrates a side view of the engagement features of thehousing of the twist-lock mounting assembly of FIG. 2 causing thelocking pin to rotate toward a released position in accordance with animplementation of the present invention;

FIG. 4C illustrates a side view of a locking pin being inserted past theengagement features of the housing of the twist-lock mounting assemblyof FIG. 2 and engaging a crown disk of the twist-lock mounting assemblyof FIG. 2 in accordance with an implementation of the present invention;

FIG. 4D illustrates a side view of the crown disk of the twist-lockmounting assembly of FIG. 2 causing a locking pin to rotate from thereleased position toward the locked position in accordance with animplementation of the present invention;

FIG. 4E illustrates a side view of the engagement features of thehousing of the twist-lock mounting assembly of FIG. 2 causing a lockingpin to rotate into the locked position in accordance with animplementation of the present invention;

FIG. 4F illustrates a side view of a locking pin being refracted into alocking channel of the housing of the twist-lock mounting assembly ofFIG. 2 in accordance with an implementation of the present invention;

FIG. 5A illustrates a side view of a locking pin being inserted from thelocked position past the engagement features of the housing of thetwist-lock mounting assembly of FIG. 2 and engaging a crown disk of thetwist-lock mounting assembly of FIG. 2 in accordance with animplementation of the present invention;

FIG. 5B illustrates a side view of a crown disk of the twist-lockmounting assembly of FIG. 2 causing a locking pin to rotate from thelocked position toward the released position in accordance with animplementation of the present invention;

FIG. 5C illustrates a side view of a locking pin being retracted towardthe engagement features of the housing of the twist-lock mountingassembly of FIG. 2 in accordance with an implementation of the presentinvention;

FIG. 5D illustrates a side view of the engagement features of thehousing of the twist-lock mounting assembly of FIG. 2 causing a lockingpin to rotate into the released position in accordance with animplementation of the present invention;

FIG. 6 illustrates an interior view of a housing in cross-section of atwist-lock mounting assembly in accordance with an implementation of thepresent invention;

FIG. 7 illustrates a schematic view of a panel system including aplurality of panels mounted to a support structure via a plurality oftwist-lock mounting assemblies;

FIG. 8 illustrates an enlarged side-view of the melt-bondable panelmounting bracket of FIG. 1;

FIG. 9 illustrates an elevated, side perspective-view of themelt-bondable panel mounting bracket of FIG. 8;

FIG. 10 illustrates an elevated, bottom perspective view of anothermelt-bondable panel mounting bracket in accordance with animplementation of the present invention;

FIG. 11 illustrates an elevated, top perspective view of themelt-bondable panel mounting bracket of FIG. 10;

FIG. 12 illustrates a side view of the melt-bondable panel mountingbracket of FIG. 10 secured within a resin-based panel in accordance withan implementation of the present invention;

FIG. 13 illustrates an enlarged cross-sectional view of themelt-bondable panel mounting bracket and panel of FIG. 12 taken alongthe line 13-13 of FIG. 12;

FIG. 14 illustrates a bottom perspective-view of a melt-bondable panelmounting bracket in accordance with an implementation of the presentinvention;

FIG. 15 illustrates a bottom perspective-view of a melt-bondable panelmounting bracket in accordance with another implementation of thepresent invention;

FIG. 16 illustrates a top perspective-view of the melt-bondable panelmounting bracket of FIG. 15;

FIG. 17 illustrates a top perspective-view of a melt-bondable panelmounting bracket in accordance with another implementation of thepresent invention;

FIG. 18 illustrates a bottom perspective-view of the melt-bondable panelmounting bracket of FIG. 17;

FIG. 19 illustrates an exploded, perspective-view of a melt-bondablepanel mounting bracket, resin panel, and a bracket mounting system inaccordance with an implementation of the present invention;

FIG. 20 illustrates a side cross-sectional view of the melt-bondablepanel mounting bracket, panel, and a bracket mounting system of FIG. 19;

FIG. 21 illustrates a side cross-sectional view of the melt-bondablepanel mounting bracket, panel, and a bracket mounting system of FIG. 19,albeit with the melt-bondable panel mounting bracket secured within thepanel;

FIG. 22 illustrates a top perspective-view of a melt-bondable panelmounting bracket in accordance with another implementation of thepresent invention;

FIG. 23 illustrates a bottom perspective-view of the melt-bondable panelmounting bracket of FIG. 22;

FIG. 24 illustrates a side cross-sectional of a melt-bondable panelmounting bracket, resin panel, and a bracket mounting system inaccordance with another implementation of the present invention; and

FIG. 25 illustrates a side cross-sectional view of the melt-bondablepanel mounting bracket, panel, and a bracket mounting system of FIG. 24,albeit with the melt-bondable panel mounting bracket secured within thepanel.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention is directed to systems, methods, and apparatus formounting panels as partitions, displays, barriers, treatments, or otherstructure with increased functional versatility. In particular, variouscomponents, systems, and methods described herein allow panels to bequickly and efficiently assembled and disassembled with relative ease.For example, one or more other implementations can include amelt-bondable panel mounting bracket for mounting an object, such as adecorative architectural resin-based, to a support structure. Such canprovide a secure and reliable way to mount panels that alsosignificantly reduces the time and labor needed to mount and/or dismountpanels to a structure.

For instance, such implementations allow a user to dismount the panelfrom the support structure by pressing the mounting components togethera second time, thereby releasing the locking mechanism holding themounting components together. The ability to quickly mount and dismountpanels can allow for easy access to lighting, HVAC, or other componentsbehind a panel for maintenance purpose or otherwise. Furthermore,implementations of a twist-lock mounting assembly can allow a user toquickly and easily reconfigure or otherwise change the aesthetic of agiven design space by switching or otherwise reconfiguring a set ofpanels mounted therein.

In addition to the foregoing, systems and components of the presentinvention can help reduce the likelihood of damaging the panels. Forinstance, one or more implementations allow a panel to be mounted to asupport structure by simultaneously pressing multiple mountingcomponents secured to the panel together with corresponding mountingcomponents secured to the support structure. Thus, such implementationscan eliminate the need for use of tools in close proximity to a panelduring the mounting process, and thereby reduce the likelihood ofscratching the panel. Furthermore, the ability to simultaneously connectand disconnect all mounting hardware can eliminate damage associatedwith removing individual standoffs one at a time.

In addition to providing a secure, yet easily configurable, mount of thepanels to a structure, one or more implementations can help magnify theaesthetic features of a mounted panel or set of panels. For example, oneor more implementations provide mounting hardware that reduces oreliminates the visibility of hardware. For example, one or moreimplementations include a melt-bondable panel mounting bracket that cansecurely mount panels to a support structure without covering orotherwise obscuring any portion of the surfaces of the panels beingdisplayed (i.e., the proximal display surfaces). Accordingly, a user caneasily adapt implementations of the present invention to an environmentof use and provide a number of secure mounting options.

As mentioned above, user (architects, designers, assemblers, etc.) maychoose to use components of the present invention to mount resin panelsbecause they can allow resin panels to be quickly and easily mountedwith a reduced likelihood of damage, while also providing a pleasingaesthetic. As used herein, the terms “resin panel” and “resin-basedpanel” refer to panels comprising a substrate of one or more layers orsheets formed from any one of the following thermoplastic polymers (oralloys thereof). Specifically, such materials can include, but are notlimited to, polyethylene terephthalate (PET), polyethylene terephthalatewith glycol-modification (PETG), acrylonitrile butadiene-styrene (ABS),polyvinyl chloride (PVC), polyvinyl butyral (PVB), ethylene vinylacetate (EVA), polycarbonate (PC), styrene, polymethyl methacrylate(PMMA), polyolefins (low and high density polyethylene, polypropylene),thermoplastic polyurethane (TPU), cellulose-based polymers (celluloseacetate, cellulose butyrate or cellulose propionate), or the like.

As a preliminary matter, implementations of the present invention aredescribed herein primarily with reference to mounting panels, such asresin panels. One will appreciate, however, that a panel, particularly aresin-based panel, is only one type of “structure” which a user maymount using the components, systems, and methods described herein can beused. For example, a user can use implementations of the presentinvention to mount not only resin “panels,” as such, but also glasspanels, to a given support structure. Furthermore, one will appreciatethat a user can use various components and mounting assemblies describedherein to mount other types of structures having different materialcompositions, such as objects comprising wood, stone, fiberglass, or thelike, which may or may not exhibit primarily panel-like dimensions asdescribed herein. Reference herein, therefore, to panels, or even resinpanels, as such, is primarily for convenience in description.

Referring now to the Figures, FIG. 1 illustrates a schematic diagram ofa twist-lock mounting assembly 100 secured to a resin-based panel 102.Specifically, FIG. 1 illustrates a panel 102, such as a resin-basedpanel, having a display surface 102 b and an opposing mounting surface102 a to which the twist-lock mounting assembly 100 (also referred to asa click-lock mounting assembly in some cases) is secured. As mentionedabove, the twist-lock mounting assembly 100 can securely mount one ormore panels 102 to a support structure, while allowing the panels 102 tobe quickly and efficiently assembled, disassembled, and reconfiguredwith relative ease. This is possible, at least in part, because thetwist-lock mounting assembly 100 may not require the use of multiplefasteners or other mounting hardware that require time and significanteffort to use.

For example, FIG. 1 illustrates that the twist-lock mounting assembly100 can comprise a housing 104 and a locking pin 106. As explained ingreater detail below, a user can selectably lock the locking pin 106within the housing 104 to secure the resin-based panel 102 to a supportstructure. More specifically, when a user inserts the locking pin 106within the housing 104 and presses the locking pin 106 and housing 104together a first time, the locking pin 106 can automatically lock withinthe housing 104. Similarly, when a user presses the locking pin 106 andhousing 104 together a second time, the locking pin 106 canautomatically unlock from the housing 104.

Thus, in order to secure resin-based panel 102, or a portion thereof, toa support structure, a user can secure one of the housing 104 and thelocking pin 106 to the resin-based panel 102, and the other of thehousing 104 and the locking pin 106 to a support structure (e.g., 156,FIG. 7). The user can then insert the locking pin 106 within the housing104 and press the locking pin 106 and the housing 104 together, therebylocking the locking pin 106 within the housing 104 and securing theresin-based panel 102 to the support structure. In order to dismount theresin-based panel 102 from the support structure, the user can press thelocking pin 106 and housing 104 together a second time, therebyautomatically unlocking the locking pin 106 from the housing 104. Onceunlocked from the housing 104, the user can pull the locking pin 106 outof the housing 104, and thus, dismount the resin-based panel 102 fromthe support structure.

More specifically, and as explained in greater detail below, as a userpresses the locking pin 106 and the housing 104 together a first time,one of the housing 104 and locking pin 106 can automatically rotaterelative to the other into a locked position. Once in the lockedposition, the housing 104 can prevent the locking pin 106 from beingseparated or pulled out of the housing 104. When the user presses thelocking pin 106 and the housing 104 together a second time, one of thehousing 104 and locking pin 106 can automatically rotate relative to theother from the locked position into a released position. Once in thereleased position, the housing 104 and the locking pin 106 can beseparated; and thus, the user can pull the locking pin 106 from thehousing 104, thereby dismounting the resin-based panel 102 from asupport structure.

As previously mentioned, a user can secure one of the housing 104 andthe locking pin 106 to the resin-based panel 102, and the other of thehousing 104 and the locking pin 106 to the support structure. Forexample, FIG. 1 illustrates the housing 104 secured to the resin-basedpanel 102, and the locking pin 106 free so as to be able to be securedto a support structure (e.g., via connector 110). In alternativeimplementations, however, a user can secure the locking pin 106 to theresin-based panel 102, and the housing 104 to the support structure.

Thus, one will appreciate in light of the disclosure herein that thetwist-lock mounting assembly 100 can include a first end (i.e., thehousing 104 or the locking pin 106) configured to be secured to aresin-based panel 102. For example, as shown in FIG. 1, the twist-lockmounting assembly 100 can include a panel mounting connector 108configured to secure one end (i.e., the housing 104) to the resin-basedpanel 102. As explained in greater detail below, in at least oneimplementation the panel mounting connector 108 can comprise amelt-bondable panel mounting bracket. The melt-bondable panel mountingbracket can allow a user to secure the twist-lock mounting assembly 100to the resin-based panel 102, while also hiding or concealing anyhardware from a facing view of the resin-based panel 102. Alternatively,the panel mounting connector 108 can include a standoff screw and cap, abracket, a flange, an adhesive, or other suitable hardware componentcapable of securing the twist-lock mounting assembly 100 to a panel 102.

Additionally, the twist-lock mounting assembly 100 can include a secondend (i.e., the housing 104 or the locking pin 106) configured to besecured to a support structure. For example, as shown in FIG. 1, thetwist-lock mounting assembly 100 can include a connector 110 configuredto secure the locking pin 106 to a support structure. The connector 110can include a bracket 110 as illustrated in FIG. 1. Alternatively, theconnector 110 can include a screw, a flange, an anchor, an adhesive, orother suitable hardware component capable of securing the twist-lockmounting assembly 100 to a support structure.

The twist-lock mounting assembly 100 can further include a pivotmechanism. The pivot mechanism can allow one end (i.e., the housing 104or the locking pin 106) of the twist-lock mounting assembly 100 torotate or swivel relative to the other. For example, the twist-lockmounting assembly 100 can include a pivot mechanism configured topivotally secure the panel mounting connector 108 to the housing 104. Insuch implementations, the pivot mechanism can allow the housing 104 torotate relative to the locking pin 106, into and out of the lockedposition, while the locking pin 106, resin-based panel 102, and supportstructure remain rotationally fixed.

Alternatively, FIG. 1 illustrates that the twist-lock mounting assembly100 can include a pivot pin 112 configured to pivotally secure thelocking pin 106 to the connector 110. In particular, the pivot pin 112can allow the connector 110 to freely rotate about the locking pin 106.The pivot pin 112 can thus allow the locking pin 106 to rotate relativeto the housing 104, into and out of the locked position, while thehousing 104, resin-based panel 102, and support structure remainrotationally fixed.

As discussed above, depending upon the location and configuration of thepivot mechanism, either the housing 104 or the locking pin 106 canrotate or swivel relative to the other in and out of the locked andreleased positions. To aid in the ease of description, however, theremainder of the detailed description describes the locking pin 106rotating relative to the housing 104. One will appreciate, nonetheless,that the present invention is not so limited, and that the scope of theinvention can be practiced in a wide variety of ways and with a widevariety of components in accordance with the principles disclosedherein.

FIG. 2 and the corresponding text, shows or describes particular detailsof the individual components of the twist-lock mounting assembly 100.For example, FIG. 2 illustrates that the housing 104 can include a firsthousing component 104 a and a second housing component 104 b, which, inone implementation, are effectively duplicates of each other.Additionally, FIG. 2 illustrates that the twist-lock mounting assembly100 can further include a crown disk 114. As explained in greater detailbelow, the crown disk 114 can work in conjunction with the housing 104to cause the locking pin 106 to automatically rotate relative to thehousing 104 into and out of the locked and released positions.

As FIG. 2 illustrates, the locking pin 106 can include a shaft 116, ahead 118, and an opposing tip 119. Furthermore, the locking pin 106 caninclude one or more flanges 120 or extrusions that extend radiallyoutward from the outer surface of the shaft 116. For example, FIG. 2illustrates that the locking pin 106 can include a pair of flanges 120positioned on opposing sides of the shaft 116. In alternativeimplementations, the locking pin 106 can include three, four, six, orany number of flanges 120.

Furthermore, the flanges 120 can include one or more engagement surfacesconfigured to work cooperatively with corresponding features of thehousing 104 and crown disk 114 to cause the locking pin 106 toautomatically rotate between the locked and released positions. Forexample, FIG. 2 illustrates that each flange 120 can include an upperhelical surface 122, a first lower helical surface 124, and a secondlower helical surface 126. In alternative implementations, each flange120 can comprise only one lower helical surface, or can include twoupper helical surfaces. In any event, each flange 120 can includesufficient engagement surfaces to allow the locking pin 106 toautomatically rotate relative to the housing 104, as explained ingreater detail below.

FIG. 2 illustrates that the upper helical surface 122 can extend fromthe top end (i.e., the end of the flange 120 closest to the head 118)toward the bottom end (i.e., the end of the flange 120 closest to thetip 119) of the flange 120, and counter clockwise around the shaft 116.The first lower helical surface 124 can extend from the bottom endtoward the top end of the flange 120, and clockwise around the shaft116. FIG. 2 additionally illustrates that the second lower helicalsurface 126 can extend from the bottom end toward the top end of theflange 120, and clockwise around the shaft 116.

As mentioned previously, the housing 104 can include features configuredto work in conjunction with the flanges 120 to cause the locking pin 106to automatically rotate within the housing 104(a, b). More specifically,each of the first housing component 104 a and the second housingcomponent 104 a can include one or more engagement features configuredto rotate the locking pin 106 as it is inserted and withdrawn from thehousing 104. The one or more engagement features can also lock thelocking pin 106 within the housing 104 when the locking pin 106 is inthe locked position.

For example, FIG. 2 illustrates that each housing component 104 a, 104 bcan include an upper helical ledge 128 (also referred to as a firsttapered ledge in some cases), a first lower helical ledge 130 (alsoreferred to as a second tapered ledge in some cases), a second lowerhelical ledge 132 (also referred to as a second tapered ledge in somecases), and a locking channel 134. Each of the helical ledges 128, 130,132 can extend generally radially outward from the inner surfaces 136 a,136 b of the housing components 104 a, 104 b toward the center of thehousing 104. Furthermore, the upper helical ledges 128 can extendgenerally in a direction from an upper end (i.e., the end configured toreceive the locking pin 106) toward a lower end (i.e., the endconfigured to hold the crown disk 114) of the housing 104.

Additionally, the upper helical ledges 128 can extend only partiallyaround the circumference of the inner surfaces 136 a, 136 b of thehousing components 104 a, 104 b. Thus, as shown in FIG. 3, the upperhelical ledges 128 can form a pair of grooves or openings 138. Thegrooves 138 can allow the flanges 120 of the locking pin 106 to passinto and out of the housing 104. Thus, when the locking pin 106 isrotationally aligned with the housing 104 so that the flanges 120 of thelocking pin 106 can pass through the grooves 138 in or out of thehousing 104, the locking pin 106 is in the “released position.”

Referring again to FIG. 2, in addition to upper helical ledges 128, theopening of the housing 104 can include tapered edges 141. The taperededges 141 can help guide the locking pin 106 into the housing 104. Morespecifically, the tapered edges 141 can help ensure that as a userpresses the locking pin 106 toward the housing 104, so that the lockingpin 106 will enter into the housing 104 even if the user has notcompletely aligned the locking pin 106 and the opening of the housing104.

As explained in greater detail below, when a user inserts the lockingpin 106 into the housing 104, the first and second lower helicalsurfaces 124, 126 of the locking pin 106 can engage and slide along theupper helical ledges 128. The helical configuration of the upper helicalledges 128 can cause the locking pin 106 to automatically rotate intothe released position as the user inserts the locking pin 106 into thehousing 104. One will appreciate in light of the disclosure herein thatthe upper helical ledges 128 can automatically rotate the locking pin106 into the released position no matter the initial rotationalalignment of the locking pin 106 relative to the housing 104.

Referring again to FIG. 2, the locking channels 134 can extend in adirection generally from the bottom toward the top of the housing 104toward the upper helical ledges 128. The locking channels 134 canfurther extend from the radially innermost surface of the upper helicalledges 128 radially outward toward the inner surfaces 136 a, 136 b ofthe housing 104. The locking channels 134 can additionally comprise anopening towards the bottom end of the housing 104, but have a top endenclosed by the upper helical ledges 128. Thus, locking channels 134 canprevent the flanges 120, and thus the locking pin 106, from beingwithdrawn from the housing 104. Thus, when the locking pin 106 isaligned with the housing 104 so that the flanges 120 of the locking pin106 are within the locking channels 134, the locking pin 106 is in the“locked position.”

As FIG. 2 illustrates, the first lower helical ledge 130 can extend in adirection from the bottom to the top of the housing 104, andcircumferentially along the inner surface 136 a, 136 b of the housing104. Additionally, the first lower helical ledge 130 can extend more andmore radially outward from the inner surface 136 a, 136 b of the housing104 as the first lower helical ledge 130 extends generally up thehousing 104 toward the top end of the housing 104. Along similar lines,the second lower helical ledge 132 can extend in a direction from thetop to the bottom of the housing 104, and circumferentially along theinner surface 136 a, 136 b of the housing 104.

As explained in greater detail below, when a user inserts the lockingpin 106 into the housing 104 a first time and begins withdrawing thelocking pin 106 toward the upper end of the housing 104, the upperhelical surfaces 122 of the locking pin 106 can engage and slide alongthe second helical ledge 132. The helical configuration of the secondhelical ledge 132 can cause the locking pin 106 to automatically rotateat least partially toward the locked position. Along similar lines, as auser presses the locking pin 106 toward the crown disk 114, and thenbegins withdrawing the locking pin 106 from the housing 104, the upperhelical surfaces 122 of the locking pin 106 can engage and slide alongthe first helical ledge 130. The helical configuration of the firsthelical ledge 130 can cause the locking pin 106 to automatically rotateat least partially toward the released position.

In addition to the engagement features (i.e., upper helical ledge 128,first lower helical ledge 130, and second lower helical ledge 132) ofthe housing 104, the crown disk 114 can also help rotate the locking pin106 into and out of the locked and released positions. In particular,the crown disk 114 can include a plurality of protrusions configured toreceive and rotate the locking pin 106. For example, FIG. 2 illustratesthat the crown disk 114 can include four helical protrusions 139, 140(also referred to as helical ledges in some cases). In particular, thecrown disk 114 can include a first pair of helical protrusions 139 and asecond pair of helical protrusions 140. The helical protrusions 139, 140can extend circumferentially around the housing 104 and generally towardthe upper end of the housing 104.

As explained in greater detail below, as a user presses the locking pin106 toward the crown disk 114 from the released position, the firstlower helical surfaces 124 of the locking pin 106 can engage and slidealong the first pair of helical projections 139. The helicalconfiguration of the first pair of helical projections 139 can cause thelocking pin 106 to automatically rotate at least partially toward thelocked position. Along similar lines, as a user presses the locking pin106 toward the crown disk 114 from the locked position, the first lowerhelical surfaces 124 of the locking pin 106 can engage and slide alongthe second pair of helical protrusions 140. The helical configuration ofthe second pair of helical protrusions 140 can cause the locking pin 106to automatically rotate at least partially toward the released position.

In addition to the helical protrusions 139, 140, the crown disk 114 caninclude one or more pegs 142 extending radially outward from the crowndisk 114. For example, FIG. 2 shows that the crown disk 114 can includea pair of pegs 142 disposed on opposing sides of the crown disk 114.Furthermore, as FIG. 2 illustrates, the housing 104 can includecorresponding recesses 144 configured to receive the pegs 142 of thecrown disk 114. The interlocking recesses 144 and pegs 142 can helpensure that the crown disk 114 cannot rotate relative to the housing104, which can help ensure that the protrusions 139, 140 crown disk 114remains in proper orientation relative to the engagement features of thehousing 104. One will appreciate in light of the disclosure herein thatproper alignment between the crown disk 114 and the housing 104 can helpensure that the crown disk 114 and the housing 104 can stay secure, andthus properly cause the locking pin 106 to rotate into and out of thereleased and locked positions.

As previously mentioned, one end (i.e., the locking pin 106 or the crowndisk 114) of the twist-lock mounting assembly 100 can include a panelmounting connector configured to secure the twist-lock mounting assembly100 to a panel. As shown in FIG. 2, in one implementation of the presentinvention, the twist-lock mounting assembly 100 can include amelt-bondable panel mounting bracket 108 configured to secure the crowndisk 114 to a resin-based panel 102. In the illustrated implementation,the crown disk 114 can include a male connector 146 configured to engagea corresponding female receptacle within the melt-bondable panelmounting bracket 108 (or vice versa). Alternatively, the melt-bondablepanel mounting bracket 108 and the crown disk 114 can includecorresponding features having a snap-fit engagement, or other suitableconnection capabilities.

In some implementations, the twist-lock mounting assembly 100 may notinclude a melt-bondable panel mounting bracket 108 or other panelconnector. In such implementations, the crown disk 114 can secure thetwist-lock mounting assembly 100 directly to a resin-based panel 102.For example, a user can insert the male connector 146 of the crown disk114 through a hole in the resin-based panel 102, and secure a mountingcap to the male connector 146 on the other side of the resin-based panel102.

As previously mentioned, the housing 104 can include a first housingcomponent 104 a and a second housing component 104 b. For example, FIG.3 illustrates that the first and second portions 104 a, 104 b of thehousing can include supports 150, through which a user can securefasteners, such as screws 152, to hold the first and second portions 104a, 104 b of the housing together. In alternative implementations, a usercan secure the first and second portions 104 a, 104 b of the housingtogether with adhesives, VELCRO, rivets, clips, and other fasteners.

Each of the components of the twist-lock mounting assembly 100 describedherein above with reference to FIGS. 1-3 can comprise a strong,light-weight material. For example, according to some implementations ofthe present invention, the components of the twist-lock mountingassembly 100 can each comprise a polymer, or a metal or alloy thereof,such as for example, aluminum. One will appreciate, however, that theseand other components described herein can be prepared from any number ofsynthetic or naturally occurring resins, rubbers, glass, ceramics,and/or composites thereof.

FIGS. 4A-4F, and the corresponding text, show or describe in furtherdetail the process of a user inserting a locking pin 106 into thehousing of the twist-lock mounting assembly 100 to lock the locking pin106 within the housing 104. More specifically, FIGS. 4A-4F show how auser can insert the locking pin 106 into the housing 104, therebycausing the locking pin 106 to automatically rotate relative to thehousing 104 into the locked position. As described above, once in thelocked position, the housing 104 can prevent the locking pin 106 frombeing removed therefrom.

To aid in description, FIGS. 4A-4F, and the corresponding text, describethe process of locking the housing 104 and locking pin 106 of atwist-lock mounting assembly 100 with respect to a single cross-sectioncomponent 104 a or 104 b of housing 104. One will appreciate in light ofthe disclosure herein, however, that similar or correspondinginteractions can also occur simultaneously between the locking pin 106and the other housing 104 component (or cross-section) 104 a or 104 b.

Referring now to FIG. 4A, a user can insert the locking pin 106 withinthe opening of the housing 104. As mentioned above, the tapered surfaces141 of the opening of housing 104 can help guide the locking pin 106into the housing 104. Once within the center cavity of the housing 104,the user can further insert the locking pin 106 into the housing 104 asindicated by the arrow of FIG. 4A.

As the user guides the locking pin 106 toward the crown disk 114, one ormore of the first lower helical surface 124 and the second lower helicalsurface 126 can engage and slide along the upper helical ledge 128. Thehelical configuration of the upper helical ledge 128 can guide the lowerhelical surface(s) 124, 126 along the length of the upper helical ledge128, and thereby, cause the locking pin 106 to rotate clockwise aboutits axis as shown by the arrow of FIG. 4B.

More specifically, the upper helical ledge 128 can cause the locking pin106 to rotate into the released position (i.e., the rotational positionof the locking pin 106 relative to the housing 104 illustrated by FIG.4B). In other words, the upper helical ledge 128 can cause the lockingpin 106 to rotate until the flanges 120 are aligned with the grooves 138(FIG. 3) of the housing 104. One will appreciate that the upper helicalledge 128 can cause the locking pin 106 to automatically rotate into thereleased position, regardless of the rotational orientation in which theuser originally positions the flanges 120 with respect to the upperhelical ledge 128.

Thus, depending upon the original rotational orientation of the lockingpin 106, the upper helical ledges 128 of the housing 104 can cause thelocking pin 106 to rotate between approximately 0 degrees andapproximately 90 degrees. For example, when the original rotationalorientation of the flanges 120 of the locking pin 106 are rotatedapproximately 90 degrees relative to the released position, as FIG. 4Aillustrates, the upper helical ledges 128 can cause the locking pin 106to rotate approximately 90 degrees. On the other end of the spectrum,when the original rotational orientation of the flanges 120 of thelocking pin 106 are rotationally aligned with the grooves 138, the upperhelical ledges 128 may not cause the locking pin 106 to rotate at all.

Once the housing 104 has rotated the locking pin 106 in the releasedposition, the user can further advance the locking pin 106 along thelength of the housing 104 as indicted by the arrow of FIG. 4C. Morespecifically, the user can advance the flanges 120 of the locking pin106 beyond the engagement features (i.e., 128, 130, 132) of the housing104 and into a gap between the crown disk 114 and the internal features,as FIG. 4C illustrates. One will appreciate in light of the disclosureherein that the gap, or distance, between the end of the lower helicalledges 130, 132 and the top of the helical protrusions 139, 140 canprovide a space within which the flanges 120 may rotate freely relativeto the housing 104.

As the user further advances the locking pin 106 in the housing 104, theflanges 120 of the locking pin 106 can contact and slide along the firstpair of helical protrusions 139 of the crown disk 114. In particular,the first lower helical surface 124 of each flange 120 can engage andslide along a helical protrusion of the first pair of helicalprotrusions 139. The helical shape of the first pair of helicalprotrusions 139 can cause the flanges 120 of the locking pin 106 torotate clockwise toward the locked position, as indicated by the arrowof FIG. 4D. As previously mentioned, the locked position is therotational position of the locking pin 106 relative to the housing 104when the flanges 120 are rotationally aligned with the locking channels134 of the housing 104, as illustrated in FIG. 4F.

One will appreciate in light of the disclosure herein that in order totransition from the released position to the locked position, thelocking pin 106 can rotate approximately ninety degrees about itslongitudinal axis. Thus, according to some implementations of thepresent invention, the first pair of helical protrusions 139 of thecrown disk 114 can cause the locking pin 106 to rotate betweenapproximately 1 degree and approximately 90 degrees relative to thereleased position. According to additional implementations, the firstpair of helical protrusions 139 of the crown disk 114 can cause thelocking pin 106 to rotate between approximately 20 degrees andapproximately 60 degrees relative to the released position. According toyet further implementations of the present invention, the first pair ofhelical protrusions 139 of the crown disk 114 can cause the locking pin106 to rotate approximately 45 degrees relative to the releasedposition.

In any event, once the locking pin 106 has been at least partiallyrotated toward the locked position, the user can retract the locking pin106 away from the crown disk 114, as indicated by the arrow of FIG. 4E.As shown in FIG. 4E, as the user retracts the locking pin 106 away fromthe crown disk 114, the flanges 120 can contact and slide along thesecond lower helical ledges 132 and/or the first lower helical ledges130 of the housing 104. The second lower helical ledges 132 of housing104 can cause the locking pin 106 to finish rotating into the lockedposition, as indicated by the arrow of FIG. 4F.

The amount of rotation the second lower helical ledges 132 and/or thefirst lower helical ledges 130 cause the locking pin 106 to rotate canbe based upon how much the first pair of helical protrusions 139 rotatethe locking pin. Thus, according to some implementations, the secondlower helical ledges 132 and/or the first lower helical ledges 130 cancause locking pin 106 to rotate between approximately 0 degrees andapproximately 90 degrees relative to the released position. Inadditional implementations, the second lower helical ledges 132 and/orthe first lower helical ledges 130 can cause the locking pin 106 torotate between approximately 20 degrees and approximately 60 degreesrelative to the released position. According to yet furtherimplementations of the present invention, the second lower helicalledges 132 and/or the first lower helical ledges 130 can cause thelocking pin 106 to rotate approximately 45 degrees relative to thereleased position.

In any event, once rotated into the locked position, the user canretract the locking pin 106 until the flanges 120 of the locking pin 106are positioned within locking channels 134 of the housing 104. When theflanges 120 are positioned within the locking channels 134, the lockingchannels 134 can prevent the locking pin 106 from being retracted fromthe housing 104 by the user, the weight of a panel(s) secured to thetwist-lock mounting assembly 100, or other forces.

The description herein describes the user retracting the locking pin 106from the crown disk 114 into the locking channels 134 or out of thehousing 104. Depending upon the configuration of the resin-based panel102 and support structure secured to the twist-lock mounting assembly100, however, the weight of the panel(s) or gravity acting on thelocking pin 106 can automatically force the locking pin 106 toward thelocking channels 134 or opening of the housing 104. Thus, in someimplementations, the user need only press the locking pin 106 againstthe crown disk 114, and the weight of the panel(s) 102 can force theflanges 120 of the locking pin 106 into the locking channels 134. Forexample, when a user mounts a panel(s) 102 to an overhead supportstructure, such as for example, a ceiling, the weight of the panel(s)102 (in combination with the engagement features) can force the lockingpin 106 to move from the crown disk 114 into the locking channels 134.In such implementations, the weight of the panel(s) 102 can bias flanges120 of the locking pin 106 into the locking channels 134, therebyhelping prevent the locking pin 106 from inadvertently releasing fromthe housing 104.

Additionally, according to some implementations, the twist-lock mountingassembly 100 can include a mechanism for preventing the locking pin 106from unintentionally unlocking from the housing 104, for instance, inthe cause of seismic activity. For example, twist-lock mounting assembly100 can include a securing mechanism, such as, for example, a cord, apin, a hook, etc., that independently connects the locking pin 106 andthe housing 104. Alternatively, the securing mechanism can secure theend of the twist-lock mounting assembly 100 attached to the resin-basedpanel 102 directly to the support structure. The securing mechanism canprevent a resin-based panel 102 from falling from a support structure ifthe locking pin 106 is unintentionally unlocked from the housing 104.

In some implementations, the twist-lock mounting assembly 100 caninclude a biasing mechanism configured to bias the flanges 120 of thelocking pin 106 into the locking channel 134 of the housing 104. Abiasing mechanism can help prevent the locking pin 106 frominadvertently releasing from the housing 104. Additionally, a biasingmechanism can allow a twist-lock mounting assembly 100 to mount apanel(s) to a wall or in other non-hanging configurations. For example,in some implementations, the twist-lock mounting assembly 100 caninclude a mechanical (e.g., spring), magnetic, or other mechanismconfigured to bias the locking pin 106 within the clocking channels 134.

In addition to allowing a resin-based panel 102 to be relatively easilymounted to a support structure 106, the twist-lock mounting assembly 100can also allow a panel 102 to be relatively easily dismounted from asupport structure 106. This can be particularly useful when there arebacklights, electrical components, HVAC components, or other componentsbehind the mounted panel 102 that need to be accessed from time to time.The ability to relatively quickly and easily dismount a panel canprovide significant time and effort advantages, and also prevent paneldamage common with dismounting panels using conventional hardware. Inorder to dismount the resin-based panel 102 from the support structure,a user can insert the locking pin 106 into the housing 104, therebycausing the locking pin 106 to automatically rotate relative to thehousing 104 into the released position.

FIGS. 5A-5D, and the corresponding text, show or describe in furtherdetail the process of a user inserting a locking pin 106 into thehousing 104 of the twist-lock mounting assembly 100 to unlock thelocking pin 106 from the housing 104. Referring to FIG. 5A, the user canadvance the locking pin 106 from the locked position toward the crowndisk 114, as indicated by the arrow of FIG. 5A. More specifically, theuser can advance the flanges 120 of the locking pin 106 into a gapbetween the crown disk 114 and the engagement features of the housing104.

As the user advances the locking pin 106 toward the crown disk 114, theflanges 120 of the locking pin 106 can contact and slide along thesecond pair of helical protrusions 140 of the crown disk 114. Inparticular, the first lower helical surface 124 of each flange 120 canengage and slide along a helical protrusion of the second pair ofhelical protrusions 140. The helical shape of the second pair of helicalprotrusions 140 can cause the flanges 120 of the locking pin 106 torotate clockwise toward the released position, as indicated by the arrowof FIG. 5B.

One will appreciate in light of the disclosure herein that the flanges120 can engage the second pair of helical protrusions 140 when the useradvances the locking pin 106 from the locked position toward the crowndisk 114. Thus, when a user advances the locking pin 106 from the lockedposition toward the crown disk 114, the helical protrusions 139, 140 canautomatically rotate the locking pin 106 toward the released position.In order to transition from the locked position to the releasedposition, the locking pin 106 can rotate approximately ninety degreesabout its longitudinal axis. Thus, according to some implementations,the second pair of helical protrusions 140 of the crown disk 114 cancause the locking pin 106 to rotate between approximately 1 degree andapproximately 90 degrees relative to the locked position. According toadditional implementations, the second pair of helical protrusions 140can cause the locking pin 106 to rotate between approximately 20 degreesand approximately 60 degrees relative to the locked position. Accordingto yet further implementations, the second pair of helical protrusions140 can cause the locking pin 106 to rotate approximately 45 degreesrelative to the locked position.

In any event, once the locking pin 106 has been at least partiallyrotated toward the released position, the user can retract the lockingpin 106 away from the crown disk 114, as indicated by the arrow of FIG.5C. As shown in FIG. 5D, as the user retracts the locking pin 106 awayfrom the crown disk 114, the flanges 120 can contact and slide along thefirst lower helical ledges 130 and/or the second lower helical ledges132 of the housing 104. The first lower helical ledges 130 of housing104 can cause the locking pin 106 to finish rotating into the releasedposition, as indicated by the arrow of FIG. 5D.

The amount of rotation the first lower helical ledges 130 and/or thesecond lower helical ledges 132 cause the locking pin 106 to rotate canbe based upon how much the second pair of helical protrusions 140 rotatethe locking pin 106. Thus, according to some implementations, the firstlower helical ledges 130 and/or the second lower helical ledges 132 cancause locking pin 106 to rotate between approximately 0 degrees andapproximately 90 degrees relative to the locked position. In additionalimplementations, the first lower helical ledges 130 and/or the secondlower helical ledges 132 can cause the locking pin 106 to rotate betweenapproximately 20 degrees and approximately 60 degrees relative to thelocked position. According to yet further implementations of the presentinvention, the first lower helical ledges 130 and/or the second lowerhelical ledges 132 can cause the locking pin 106 to rotate approximately45 degrees relative to the locked position.

In any event once rotated from the locked position into the releasedposition, the user can retract the locking pin 106 past the engagementfeatures. Specifically, when in the released position, the flanges 120can pass through the grooves 138 and out of the housing 104. Thus, inorder to dismount a resin-based panel 102 secured to a support structurevia a twist-lock mounting assembly 100, a user need only press thelocking pin 106 from the locked position against the crown disk 114 andthe engagement features of the housing 104 can cause the locking pin 106to automatically rotate into the released position.

As illustrated and described hereinabove, the locking pin 106 cancomprise two flanges 120, the housing 104 can comprises twocorresponding grooves 138 and two corresponding locking channels 134,and the crown disk 114 can comprise two corresponding pairs of helicalprotrusions 139, 140. One will appreciate that according to alternativeimplementations, the locking pin 106 can include one flange 120, thehousing 104 can include one corresponding groove 138 and one lockingchannel 134, and the crown disk 114 can comprise one pair of helicalprotrusions 139, 140. According to yet further implementations, thelocking pin 106 can include three or more flanges 120, the housing 104can include three or more corresponding grooves 138 and three or morelocking channels 134, and the crown disk 114 can include three or morecorresponding pairs of helical protrusions 139, 140. According to yetadditional implementations of the present invention, the number of thegrooves 138, locking channels 134, and/or pairs of helical protrusions139, 140 can be greater than the number of flanges 120.

Furthermore, the direction (i.e., counter clockwise or clockwise) of thehelical surfaces 122, 124, 126, helical ledges 128, 130, 132, andhelical protrusions 139, 140 can help determine the direction thelocking pin 106 rotates within the housing 104. For example, theillustrated implementation shows that the locking pin 106 can rotateclockwise relative to the housing 104. In alternative implementations,the helical surfaces 122, 124, 126, helical ledges 128, 130, 132, andhelical protrusions 139, 140 can be configured to automatically rotatethe locking pin 106 in a counter-clockwise direction relative to thehousing 104.

One will appreciate in light of the disclosure herein that the variousfeatures of the housing 104 and crown disk 114 that can cause thelocking pin 106 to rotate between the released and locked positions arenot limited to the configurations shown and described in relation toFIGS. 1-5D. For example, FIG. 6 illustrates that each upper helicalledge 128 of the housing 104 can include two surfaces 128 a, 128 binstead of a single surface. Thus, the upper helical ledge 128 can beconfigured in any number of ways to cause the locking pin 106 to rotateinto the released position. Similarly, the other helical components ofthe twist-lock mounting assembly 100 can include any number of differentconfigurations adapted to rotate the locking pin 106 in and out of thereleased and locked positions. Thus, one will appreciate that thedepicted and described embodiments are only illustrative of oneimplementation the present invention.

FIG. 7 illustrates a schematic diagram of a panel system 154 comprisinga plurality of decorative architectural resin-based panels 102 mountedas a treatment to a support structure 156 (e.g., ceiling) via aplurality of twist-lock mounting assemblies 100 in accordance with animplementation of the present invention. One will appreciate that theresin-based panels 102 have at least one surface 102 b that is displayedor visible to a viewer (i.e., the surfacing facing away from the supportstructure 156). In other words, because the resin-based panels 102 aresecured to an end of the twist-lock mounting assembly 100, the surfaceopposite to which the twist-lock mounting assembly 100 is secured willbe visible to a viewer. Accordingly, a user can configure the panel(s)102 to provide a desired aesthetic.

For example, the panel(s) 102 can be transparent, translucent, and/orcolored, as desired. When the system includes transparent or translucentresin-based panels 102, in some implementations the twist-lock mountingassembly 100 can be at least partially (if not entirely) hidden fromview at least in part since none of the components of the twist-lockmounting assembly 100 may extend completely through any such resin-basedpanel(s) 102 (e.g., via any perforations therein). Furthermore, a usercan form the resin-based panel(s) 102 to include embedded two orthree-dimensional objects such as thatch, willow reed, coffee beans,bamboo, and similar objects in order to provide a desired aesthetic.Thus, one will appreciate that a user can create a desired aesthetic forthe resin-based panel(s) 102 including any number or combinations ofdifferent features (e.g., color, transparency, surface texture, embeddedobjects, or printed images). Furthermore, a user can mount a variety ofresin-based panels 102 each with similar or different aesthetic featuresto provide a desired overall aesthetic.

As previously discussed above, according to some implementations of thepresent invention, the twist-lock mounting assemblies 110 can secure theresin-based panels 102 to the support structure 100 in a manner that thevisibility of the twist-lock mounting assemblies 100 is reduced oreliminated. For example FIG. 7 illustrates that no hardware may protrudefrom the display surface (i.e., the proximal, visible outside surface ofthe panels 102). According to alternative implementations, however, ascrew, standoff cap, or other portion of a panel mounting connector 108may protrude from the display surface 102 b of a mounted resin-basedpanel 102.

The twist-lock mounting assemblies 100 can secure the resin-basedpanel(s) 102 at a standoff position from the support structure 156. Inparticular, height of the housing 104 and locking pin 106 when lockedtogether can determine the length of the standoff at which thetwist-lock mounting assembles 100 secure the resin-based panel(s) 102 tothe support structure 156. Thus, a user can configure the height oftwist-lock mounting assemblies 100 based on a desired standoff length.For example, according to some implementations, a user may desire, orthe design space may, require a reduced standoff. In such cases, theuser can configure the housing 104 and/or locking pin 106 with a reducedheight. According to alternative implementations, the user may desire,or the design space may require, a larger standoff in order to create adesired acoustic, heating, visual, or other functional or aestheticeffect. In such cases, the user can configure the height of the housing104 and/or locking pin 106 accordingly.

For example, according to some implementations of the present invention,the resin-based panel(s) 102 can be backlit via one or more lightsources (not shown). In such implementations, it may be desirable to usea twist-lock mounting assembly 100 with sufficient height to help ensurethat the various components of the twist-lock mounting assembly 100 (ortheir shadows) are not noticeably visible through the resin-basedpanel(s) 102. Additionally, the mounting surface 102 a of theresin-based panel(s) 102, can include a diffuser film (not shown) tohelp evenly distribute light across the resin-based panel(s) 102. Insuch implementations, the user may desire to use a twist-lock mountingassembly 100 with sufficient height to help ensure there is enough spaceto effectively diffuse the light. According to yet additionalimplementations, the user may desire to use a twist-lock mountingassembly 100 with sufficient height to help create an acoustic effect,create space for storing a backlight or other components, or provideincreased insulation. In any event, a user can select an appropriatelysized twist-lock mounting assembly 100 based upon an intendedenvironment of use.

As mentioned hereinabove, according to some implementations, a panelmounting connector 108 can secure one end of the twist-lock mountingassembly 100 to a resin-based panel 102. Although not seen in FIG. 7,one or more melt-bondable panel mounting brackets 108 (FIG. 1) cansecure each resin-based panel 102 of the plurality of panels 102 to thesupport structure 156. The melt-bondable panel mounting brackets 108, incombination with the twist-lock mounting assemblies 100, can securelymount the resin-based panels 102 without damaging them, while alsohelping to magnify the aesthetic features of the resin-based panels 102.

For example, a user can heat and insert a portion of a melt-bondablepanel mounting bracket 108 directly into the mounting surface 102 a(FIG. 1) of a resin-based panel 102, albeit without passing completelythrough the resin-based panel 102. Thus, as shown in FIG. 7, themelt-bondable panel mounting brackets 108 can allow a twist-lockmounting assembly 100 to securely mount each resin-based panel 102 tothe support structure 156 without covering or otherwise obscuring anyportion of the display surfaces 102 b of the resin-based panels 102.Furthermore, according to one or more implementations, the melt-bondablepanel mounting brackets 108 and twist-lock mounting assembly 100 can becompletely hidden from view. For example, FIG. 7 illustrates theresin-based panels 102 can be opaque, and can hide or conceal themelt-bondable panel mounting brackets 108 and twist-lock mountingassembly 100 from a facing view.

In alternative implementations, the resin-based panels 102 can betransparent or translucent. Thus, the melt-bondable panel mountingbrackets 108 and twist-lock mounting assembly 100 may be at leastpartially visible through the resin-based panels 102. In suchimplementations, the melt-bondable panel mounting brackets 108 can havea color corresponding with the color of a resin-based panel 102. Thus,the melt-bondable panel mounting brackets 108 a can blend in with theresin-based panel 102 and reduce their visibility. According toadditional implementations, the melt-bondable panel mounting brackets108 can have a color configured to increase their visibility through atransparent or translucent resin-based panel 102.

Just as various other panel connectors can secure an end of a twist-lockmounting assembly 100 to a resin-based panel 102, the variousmelt-bondable panel mounting brackets 108 of the present invention cancouple other hardware components besides a twist-lock mounting assembly100 to a resin-based panel 102. Thus, a user can use the variousmelt-bondable panel mounting brackets 108 described herein to secure aresin-based panel 102 to a support structure 156 in connection with, orindependent of, a twist-lock mounting assembly 100. For example, a usercan use a melt-bondable panel mounting bracket 108 in combination withstandoff barrels, rods, cables, anchors, frames, or other hardwarecomponents or assemblies.

FIGS. 8 and 9 show a side view, and a bottom perspective-view of themelt-bondable panel mounting bracket 108, respectively. As such, FIGS. 8and 9 illustrate that the melt-bondable panel mounting bracket 108 caninclude a body 160 that can include a bonding surface. As used herein,the term “bonding surface” refers to a surface(s) configured to beheated and pressed against the resin of a resin-based panel 102.

As mentioned previously, a user can press the melt-bondable panelmounting bracket 108 directly into the resin of a resin-based panel 102.To aid in creating a bond between the melt-bondable panel mountingbracket 108 and a resin-based panel 102, the melt-bondable panelmounting bracket 108 can include one or more bonding features. Forexample, FIG. 8 illustrates that the bonding features can include abonding protrusion 164 extending generally longitudinally away from thebody 160.

Furthermore, one or more surfaces of the bonding protrusion 164 caninclude one or more roughened surfaces (e.g., ridged surfaces) or otherfeatures to increase the surface area to which resin can be bonded. Forexample, FIGS. 8 and 9 illustrate that the bonding protrusion 164 caninclude at least one bonding recess 166 extending therein in a generallylateral or transverse direction. As FIGS. 8 and 9 illustrate, eachbonding recess 166 (also referred to as a groove in some cases) can atleast partially define a ridge 167 extending generally laterally ortransversely away from the bonding protrusion 164. Each ridge 167 (alsoreferred to as a projection in some cases) can increase the surface areaof the bonding protrusion 164, and thus, can help create a stronger bondbetween the resin and the melt-bondable panel mounting bracket 108.

FIG. 9 illustrates that melt-bondable panel mounting bracket 108 caninclude a single bonding protrusion 164 having an essentially circularshape. According to additional embodiments, however, the melt-bondablepanel mounting bracket 108 can include any number of bonding protrusions164 arranged in any number of configurations. For example, the bondingprotrusion(s) 164 can have a linear, semi-circular, crossing, or otherconfiguration. Furthermore, according to some implementations, thebonding protrusions 164 can have an aesthetically pleasing size andconfiguration. For example, the bonding protrusion(s) 164 can formvarious geometric shapes, such as, for instance, stars, circles,letters, or trade symbols. Thus, in some implementations, the bondingprotrusion 164 can be at least partially visible through the resin-basedpanel 102 and add a desired aesthetic to a panel system 154.

To secure the melt-bondable panel mounting bracket 108 to a panel, auser can heat and then insert melt-bondable panel mounting bracket 108directly into a surface of the resin-based panel 102. One willappreciate that the temperature to which the user heats themelt-bondable panel mounting bracket 108 can vary depending upon thetype of resin-based panel 102 used. For example, a user can heat themelt-bondable panel mounting bracket 108 to a temperature between about150 degrees Fahrenheit and about 400 degrees Fahrenheit. Once heated,the user can apply approximately 50 psi to approximately 300 psi to themelt-bondable panel mounting bracket 108 to force the melt-bondablepanel mounting bracket 108 into a panel 102. In additionalimplementations, a user can heat the melt-bondable panel mountingbracket 108 to a temperature of between about 100 and about 500 degreesFahrenheit and apply between approximately 20 psi and approximately 100psi to bond the melt-bondable panel mounting bracket 108 to a panel 102.

As a user inserts the heated bonding protrusion 164 into a resin-basedpanel 102, the resin can melt and can flow into the bonding recesses 166and around the bonding ridges 167. The resin of the resin-based panel102 can then solidify, thereby sealing the bonding protrusion 164 intothe resin-based panel 102. Thus, the bonding recesses 166 in combinationwith the ridge 167 can help mechanically prevent the melt-bondable panelmounting bracket 108 from being pulled out of the resin of a resin-basedpanel 102.

Each bonding protrusion 164 can include any number of bonding recesses166 or ridges 167. For example, FIG. 9 illustrates that the bondingprotrusion 164 can include three bonding recesses 166 and three ridges167. In alternative implementations, the bonding protrusion 164 caninclude one, two, three, or any number of bonding recesses 166 or ridges167.

The strength of the bond between the melt-bondable panel mountingbracket 108 and a resin-based panel 102, and thus, the weight which themelt-bondable panel mounting bracket 108 a may support, may be based atleast in part upon the number and size of the bonding protrusion 164,bonding recesses 166, and/or ridges 167. Indeed, some implementationscan include a greater number and/or a larger size of protrusions 164,recesses 166, or ridges 167, and thus, be configured for use with largeror heavier panels 102. On the other hand, some implementations caninclude a smaller number and/or size of bonding protrusions 164,recesses 166, or ridges 167, to allow a user to use the melt-bondablepanel mounting bracket 108 with smaller gauged panels 102.

For example, the resin-based panel 102 can have a thickness or gaugebetween about one-eighth inch (⅛″) and about five inches (5″), orthicker. The melt-bondable panel mounting bracket 108 can have a sizeand configuration depending upon the size and gauge of the resin-basedpanel 102. For example, the various bonding features (164, 166, 167,168, 170) can have various configurations and sizes depending on thethickness of the resin-based panels 102 with which they are used.

In addition to the bonding protrusion(s) 164, the melt-bondable panelmounting bracket 108 can include additional bonding features that canaid in forming and strengthening a mechanical bond between themelt-bondable panel mounting bracket 108 and a resin-based panel 102.For example, FIG. 9 illustrates that the melt-bondable panel mountingbracket 108 can include a channel 170 extending into the body 160. Thechannel 170 can receive resin displaced by the bonding protrusions 164as a user inserts the melt-bondable panel mounting bracket 108 in to aresin-based panel 102.

As mentioned previously, the melt-bondable panel mounting bracket 108can secure a hardware component, such as for example, a twist-lockmounting system 100, to a resin-based panel 102. More specifically, themelt-bondable panel mounting bracket 108 can include a connection memberconfigured for attachment to a hardware component. For example, FIG. 8illustrates that the melt-bondable panel mounting bracket 108 caninclude a female receptacle 174 configured to receive a correspondingmale member. In some implementations, the female receptacle 174 caninclude internal threads. As alluded to earlier, the female receptacle174 can receive and secure a male connector 146 of a crown disk 114 of atwist-lock mounting system 100 (FIG. 2) therein.

Alternatively, the female receptacle 174 can receive and secure thereinan end of correspondingly rod of another hardware component, such as forexample, a standoff barrel. In additional implementations, theconnection member of the melt-bondable panel mounting bracket 108 maynot be a female receptacle. For example, the connection member canreceive a portion of a cable or otherwise allow a user to suspend aresin-based panel 102 from a support structure. Thus, one willappreciate in light of the disclosure herein that the melt-bondablepanel mounting bracket 108 can allow a user to secure a resin-basedpanel 102 to a support structure using a wide variety of differentintermediate hardware options.

FIGS. 10-13 illustrate another implementation of a melt-bondable panelmounting bracket 108 a. Similar to the melt-bondable panel mountingbracket 108 described hereinabove, the melt-bondable panel mountingbracket 108 a can include a connection member 174, a body 160, a bondingprotrusion 164, bonding recesses 166, and ridges 167. Additionally, FIG.10 illustrates that the melt-bondable panel mounting bracket 108 a canalso include one or more flow ways 168. The flow ways 168 can aid informing a mechanical bond between the melt-bondable panel mountingbracket 108 a and a resin-based panel 102.

For example, the flow ways 168 can help ensure that a portion of resinis not “stamped out” from the rest of the resin of the resin-based panel102 when the melt-bondable panel mounting bracket 108 a is secureddirectly into a resin-based panel 102. More specifically, the flow ways168 can extend between and separate the bonding protrusion 164 intoseparate portions 164 a-d, and thus, prevent the bonding protrusions 164from isolating a portion of the resin of a resin-based panel 102.Furthermore, at least a portion of resin displayed by the one or morebonding protrusions 164 can flow through—or be displayed into—the one ormore flow ways 168.

Additionally, in some implementations, the melt-bondable panel mountingbracket 108 a can include one or more perforations. For example, FIGS.10 and 11 illustrate that the melt-bondable panel mounting bracket 108 acan include a perforation 172 at the base of each of the bondingprotrusion 164. The perforations 172 can extend at least partiallythrough the melt-bondable panel mounting bracket 108 a. In someimplementations, the perforations 172 can extend completely through themelt-bondable panel mounting bracket 108 a. For example, FIGS. 10 and 11illustrate that the perforations 172 can extend from the mountingsurface 160 through the melt-bondable panel mounting bracket 108 a to atop surface 162.

The perforations 172 can receive at least a portion of the heated resindisplaced by the bonding protrusions 164 when a user inserts themelt-bondable panel mounting bracket 108 a into a resin-based panel. Inparticular, the displaced resin can flow through the perforations 172and onto the top surface 162 of melt-bondable panel mounting bracket 108a. Resin extending through the perforations 172 and onto the top surface162 can help prevent the melt-bondable panel mounting bracket 108 a frombeing pulled out of the resin-based panel 102 by sealing themelt-bondable panel mounting bracket 108 a to the resin-based panel 102.Thus, the perforations 172 can help increase the strength of the bondbetween the melt-bondable panel mounting bracket 108 a and a resin-basedpanel 102 by helping to essentially entangle various ridges andperforations of the melt-bondable bracket with eventually-solidifiedresin.

For example, FIG. 12 illustrates a side view of a melt-bondable panelmounting bracket 108 a affixed into a resin-based panel 102. To affixthe melt-bondable panel mounting bracket 108 a to the resin-based panel102, a user can place a heated melt-bondable panel mounting bracket 108a into a surface 102 a of a resin-based panel 102. The heatedmelt-bondable panel mounting bracket 108 a can heat the resin of theresin-based panel 102, thereby increasing the viscosity of the resin.The various features of the melt-bondable panel mounting bracket 108 acan displace the resin as the user inserts the melt-bondable panelmounting bracket 108 a into the resin-based panel 102. For example, theprotrusion 164 can displace or otherwise cause resin 103 to flow throughthe perforations 172 onto the top surface 162. The displaced resin 103on the top surface 162 of the melt-bondable panel mounting bracket 108 acan help create and ensure a strong bond as previously mentioned.

Additionally, as FIG. 13 illustrates, resin can flow into the bondingrecesses 166 and around or over the ridges 167. As mentioned previously,the bonding recesses 166 and ridges 167 can extend generally laterallyinto the bonding protrusions 164. FIG. 13 illustrates, in someimplementations, the bonding recesses 166 and ridges 167 can extend in adirection substantially orthogonal to the direction in which a userinserts the melt-bondable panel mounting bracket 108 a into theresin-based panel 102. Thus, resin in the bonding recesses 166 canreside longitudinally between the body 160 and a ridge 167, and thus,seal the ridges 167 within the resin of the resin-based panel 102.

Thus, the bonding features of the melt-bondable panel mounting bracket108 a can create a relatively strong bond with a resin-based panel 102.In particular, in some implementations, each melt-bondable panelmounting bracket 108 a affixed directly into a resin-based panel 102 canhold between approximately 300 and approximately 700 pounds. Thus, a setof four melt-bondable panel mounting bracket 108 a can hold or supportapproximately 2000 pounds. As such, a user can use implementations ofmelt-bondable panel mounting brackets 108 a in a wide variety of designapplications. For example, melt-bondable panel mounting bracket 108 a ofthe present invention may be particularly suited for hanging panels froma ceiling or other support structure.

FIGS. 12 and 13 additionally illustrate that a user/assembler can selectan appropriate size of melt-bondable panel mounting bracket 108 a basedat least on part of the thickness or gauge of the resin-based panel 102.For example, FIG. 12 illustrates that the resin-based panel 102 can havea gauge or thickness 178 extending between the bonding surface 102 a andthe display surface 102 b. The user can select a melt-bondable panelmounting bracket 108 a that will extend into, but not entirely throughthe thickness 178 of the resin-based panel 102. Thus, the bondingprotrusions 164 can have a height 180 less than the thickness 178 of theresin-based panel 102. In this manner, when a user fully inserts themelt-bondable panel mounting bracket 108 a into the resin-based panel102, the bonding protrusions 166 can extend a distance into theresin-based panel 102 less than the thickness 178 of the resin-basedpanel 102.

As the differences between the melt-bondable panel mounting brackets 108and 108 a illustrate, various implementations of the melt-bondable panelmounting bracket can include a variety of different configurationswithout departing from the scope and spirit of the present invention.For example, FIGS. 14-18 illustrate yet additional implementations ofmelt-bondable panel mounting brackets 108 b, 108 c, 108 d, including yetfurther configurations and/or modifications. For example, althoughdepicted as a threaded female receptacle 174 in FIGS. 8-13, theconnection member of the melt-bondable panel mounting bracket is not solimited, and may comprise any number of different connectors. Forexample, FIG. 14 illustrates that the melt-bondable panel mountingbracket 108 c can include a threaded rod 176 for a connection member. Auser can secure the threaded rod 176 within a frame, an anchor, or otherhardware component, which the user can in turn secure to a supportstructure.

As mentioned previously, the melt-bondable panel mounting bracket 108can include a channel configured to receive displaced resin as a userinserts the melt-bondable panel mounting bracket 108 into a resin-basedpanel 102. In alternative implementations, however, the melt-bondablepanel mounting bracket 108 may not include a channel. For example, FIG.14 illustrates that instead of an annular channel 170 (FIG. 8), thechannel 170 can comprise a generally circular channel 170 a extendinginto the center of the melt-bondable panel mounting bracket 108 b.Additionally, some implementations can include a channel 170 a thatextends not only partially, but completely through the melt-bondablepanel mounting bracket 108 b. Thus, in addition to receiving a portionof resin displaced by the bonding protrusion 164, the channel 170 a canreceive the connection member or other hardware. For example, FIG. 15illustrates the channel 170 a can receive a fastener having a threadedrod 176.

Similar to melt-bondable panel mounting brackets 108, 108 a, FIG. 14illustrates that melt-bondable panel mounting bracket 108 b can includea bonding protrusion 164 extending generally away from a body 160. Thebonding protrusion can include four annular portions separated by flowways 168. The bonding protrusion 164 can include both bonding recesses166 and ridges 167. In particular, FIG. 14 illustrates that the bondingprotrusion 164 can include four bonding recesses 166 and four ridges167.

FIGS. 15 and 16 illustrate yet an additional implementation of amelt-bondable panel mounting bracket 108 c. As an initial matter, themelt-bondable panel mounting bracket 108 c can comprise sheet metal.Thus, to form the melt-bondable panel mounting bracket 108 c, a user canstamp a pattern out from a piece of sheet metal, and then bend orotherwise mold the stamp to form the melt-bondable panel mountingbracket 108 c. A sheet metal configuration can allow for reducedmanufacturing costs and time.

The melt-bondable panel mounting bracket 108 c can include a connectionmember 174 configured to allow a user to connect the melt-bondable panelmounting bracket 108 c to a twist-locking mounting assembly 100 or otherhardware component. Additionally, the melt-bondable panel mountingbracket 108 c can include a bonding protrusion and a plurality ofbonding recesses 166 a extending generally laterally into the bondingprotrusion 164 e. The bonding recesses 166 a can help define ridges 167a, which extend in a generally lateral direction away from the bondingprotrusion 164 c.

More specifically, FIGS. 15 and 16 illustrate that the bonding recesses166 a can extend completely through the bonding protrusion 164 e. Thebonding recesses 166 a can include any number of shapes andconfigurations. For example, FIGS. 15 and 16 illustrates that eachbonding recess 166 a can include a trapezoidal shape. Alternatively,each bonding recess 166 a can include a square, oval, trapezoidal, orother cross-sectional shape.

Additionally, in some implementations the bonding recesses 166 a canextend both laterally through—and longitudinally into—the bondingprotrusion 164. For example, FIGS. 15 and 16 illustrate that the bondingrecesses 166 a can have a longitudinal opening separating opposingridges 167 a. One will appreciate in light of the disclosure herein thatan open configuration can allow resin to flow longitudinally betweenridges 167 a and into the bonding recesses 166 a. Thus, the openconfiguration of the bonding recesses 166 a can allow a user torelatively quickly insert the melt-bondable panel mounting bracket 108 cinto the resin of a resin-based panel 102, and thus case the mountingbracket 108 c to be essentially entangled with eventually-hardened panelmatrix material (e.g., resin).

In alternative implementations, the bonding recesses 166 a can include aclosed configuration. For example, the ridges 167 a can extend laterallyacross the bonding recesses 166 a so that the bonding recesses 166 a donot have a longitudinal opening. In a closed configuration, resin canflow longitudinally along the ridges 167 a, and then laterally over theridges 167 a into the bonding recesses 166 a. Thus, resin can wraparound the ridges 167 a, thereby sealing and entangling themelt-bondable panel mounting bracket 108 c into a resin-based panel 102.

FIGS. 17 and 18 illustrate an additional implementation of amelt-bondable panel mounting bracket 108 d. As FIGS. 17 and 18illustrate, the melt-bondable panel mounting bracket 108 d can include abody 160 and four bonding protrusions 164 f extending generally awayfrom the body 160. Each of the bonding protrusions 164 f can include aridge 167 b extending in a generally transverse direction from thebonding protrusions 164 f. Thus, as explained above in relation to theother melt-bondable panel mounting brackets 108 d, a user can heat andpress the melt-bondable panel mounting bracket 108 d into a resin-basedpanel 102. The heated melt-bondable panel mounting bracket 108 d cancause the resin of the panel 102 to flow around and over the bondingprotrusions 167 b, thereby sealing and entangling the melt-bondablepanel mounting bracket 108 d into the resin-based panel 102.

One will appreciate that melt-bondable panel mounting bracket 108 d maybe particularly suitable for use with transparent or translucent panels102. In particular, the increased height of the bonding protrusions 167f can ensure that the body 160 of the melt-bondable panel mountingbracket 108 d is positioned farther from the panel to reduce itsvisibility through or behind the panel 102. Additionally, the ridges 167b can be configured so as to be strong enough to ensure an adequatebond, but at the same time small enough to not to distract from theaesthetics of a given panel 102.

The melt-bondable panel mounting bracket 108 d can also include aconnection member 174 a configured to allow a user to secure themelt-bondable panel mounting bracket 108 d, and thus a panel 102, to anadditional hardware component. For example, FIGS. 17 and 18 illustratesthat the connection member 174 a can include a slot extending into thebody 160 of the melt-bondable panel mounting bracket 108 d betweenadjacent bonding protrusions 164 f. One will appreciate that a user canslide the slot of the connection member 174 a about a screw, anchor,cable, or other hardware component to secure the melt-bondable panelmounting bracket 108 d to a support structure. Furthermore, FIG. 18illustrates that the connection member 174 a can include a recessedgroove 182 within the body 160 of the melt-bondable panel mountingbracket 108 d. The recessed grove 182 can receive a portion of anadditional hardware component (e.g., the head of a fastener) and helpsecure the melt-bondable panel mounting bracket 108 d to a supportstructure.

As previously discussed, in one or more implementations a user cansecure a melt-bondable panel mounting bracket 108 to a panel 102 byheating and pressing the melt-bondable panel mounting bracket 108 intothe resin of the panel 102. In one or more additional implementations, auser secure a melt-bondable panel mounting bracket 108 to a panel 102using rotation in addition, or alternatively, to heat and pressure. Inparticular, in one or more implementations, a user can use high-speedrotation to advance a melt-bondable panel mounting bracket 108 into aresin-based panel 102.

For example, a user can rotate the melt-bondable panel mounting bracket108 at high speeds while advancing the melt-bondable panel mountingbracket 108 into the resin of a panel 102. The rotation of themelt-bondable panel mounting bracket 108, and the friction associatedtherewith, can cause the resin to melt about the ridges 167 and otherbonding features. The resin of the panel 102 can then solidify, therebysealing the bonding protrusion(s) 164 of the melt-bondable panelmounting bracket 108 into the resin-based panel 102.

One will appreciate in light of the disclosure herein, that the use ofrotation instead of heat can allow a user to immediately handle themelt-bondable panel mounting bracket 108 after insertion into a panel102. Indeed, the user would not have to wait for the melt-bondable panelmounting bracket 108 to cool before handling or securing a twist-lockmounting assembly 100 or other hardware component thereto. Specifically,the use of high speed rotation can cause the resin of the panel 102 tomelt, while not significantly raising the temperature of themelt-bondable panel mounting bracket 108.

According to one or more implementations, a user can use a bracketmounting system to aid in rotating a melt-bondable panel mountingbracket 108 into a panel 102. As explained in greater detailed below,the bracket mounting system can help ensure that the melt-bondable panelmounting bracket 108 advances a proper or desired distance into thepanel 102. Additionally, the bracket mounting system can help a useralign and insert the melt-bondable panel mounting bracket 108 in adesired location/position on the panel 102.

For example, FIG. 19 illustrates one implementation of a bracketmounting system 180. The bracket mounting system 180 can include a drillinterface 182, a fender 184, and a stop guide 186. The drill interface182 can couple the melt-bondable panel mounting bracket 108 to arotation tool, such as a high-speed drill. For instance, FIG. 19illustrates that the drill interface 182 can comprise a hex nut 182,which a user can secure into the mounting connector 174 of themelt-bondable panel mounting bracket 108. The user can then secure ahigh-speed drill or other rotation tool to the hex nut 182 eitherdirectly or via a socket.

As shown in FIG. 19, the drill interface 182 can also couple the fender184 to the melt-bondable panel mounting bracket 108. In particular, FIG.19 shows that the fender 184 can comprise a washer 184 that a user cansecure between the hex nut 182 and the melt-bondable panel mountingbracket 108. FIG. 19 further illustrates that the fender 184 can have aradius greater than the radius of the melt-bondable panel mountingbracket 108.

In addition to the fender 184 and the drill interface 182, the bracketmounting system 180 can also include a stop guide 186. The stop guide186 can interface with the fender 184 to control the distance themelt-bondable panel mounting bracket 108 is inserted into the panel 102.As shown in FIG. 19, the stop guide 186 can include an inner recess 188having a size and shape to allow a user to insert a melt-bondable panelmounting bracket 108 therein.

Referring now to FIGS. 19-21, a user can secure a melt-bondable panelmounting bracket 108 into a panel 102 using a bracket mounting system180. For example, the user can drill a guide hole 190 into a mountingsurface 102 a of the panel 102. In some implementations, as shown byFIGS. 20-21, the user can drill the guide hole 190 completely throughthe panel 102 from the opposing mounting surface 102 a to the displaysurface 102 b. In alternative implementations, the user can drill theguide hole 190 only partially through the panel 102.

At this point, or before if desired, the user can secure the drillinterface 182 through the fender 184 and into the connection member 174of the melt-bondable panel mounting bracket 108. The user can then theposition the guide stop 186 on the panel 102 about the guide hole 190.Thereafter, the user can insert the melt-bondable panel mounting bracket108 into the cavity 188 of the guide stop 186.

To help ensure that the melt-bondable panel mounting bracket 108 isproperly aligned, the user can also insert an alignment stem 192 intothe guide hole 190. As shown by FIGS. 20 and 21, in one or moreimplementations, the alignment stem 192 can comprise acylindrically-shaped column. To allow a user to insert the alignmentstem 192 into the guide hole 190, the alignment stem 192 can extendfarther from the melt-bondable panel mounting bracket 108 than thebonding protrusion(s) 164.

With the alignment stem 192 placed within the guide hole 190, the usercan then employ a rotational tool to rotate the melt-bondable panelmounting bracket 108 into the panel 102. In particular, the user cansecure a power driver or high-speed rotational drill to the drillinterface 186. The user can then use the power driver to rotate themelt-bondable panel mounting bracket 108 at a high rate of rotation. Forexample, the user can use the power driver to rotate the melt-bondablepanel mounting bracket 108 at between about 1700 revolutions per minuteand about 2200 revolutions per minute. In alternative implementations,the user can spin the melt-bondable panel mounting bracket 108 at lowerspeeds than about 1700 revolutions per minute or higher speeds thanabout 2200 revolutions per minute.

The user can hold the guide stop 186 to prevent it from rotating. Uponrotation, the user can apply moderate downward pressure to advance thebonding protrusion(s) 164 of the melt-bondable panel mounting bracket108 into the panel 102. One will appreciate that the ridges 167 canfunction as threads and help advance the melt-bondable panel mountingbracket 108 into the panel 102. The user can advance the melt-bondablepanel mounting bracket 108 until the fender 184 comes into contact withthe guide stop 186. Specifically, the fender 184 and guide stop 186 canprevent further advancement of the melt-bondable panel mounting bracket108. One will appreciate in light of the disclosure herein that theguide stop 186 can have a size and configuration to prevent a user fromadvancing the melt-bondable panel mounting bracket 108 too far into thepanel 102.

As alluded to earlier, the rotation of the melt-bondable panel mountingbracket 108 into the resin of a panel 102, and the friction associatedtherewith, can cause the resin to melt about the ridges 167 and otherbonding features. The resin of the panel 102 can then solidify, therebysealing the bonding protrusion(s) 164 of the melt-bondable panelmounting bracket 108 into the resin-based panel 102. Thus, the bondingrecesses 166 in combination with the ridge 167 can help mechanicallyprevent the melt-bondable panel mounting bracket 108 from being pulledout of the resin of a resin-based panel 102. In some implementations, auser can additionally secure a fastener (not shown), such as a cappedscrew, into the alignment stem 192 from the display surface 102 b sideof the panel 102 to provide an additional force to hold themelt-bondable panel mounting bracket 108 to the panel 102.

One will appreciate in light of the disclosure herein that one or moreimplementations of a melt-bondable panel mounting bracket 108 caninclude various features to aid in rotating the melt-bondable panelmounting bracket 108 into a panel. For example, FIGS. 22 and 23illustrate another implementation of a melt-bondable panel mountingbracket 108 e. Similar to the melt-bondable panel mounting bracket 108described hereinabove, the melt-bondable panel mounting bracket 108 ecan include a connection member 174, a body 160, a bonding protrusion164, bonding recesses 166, and ridges 167. Additionally, FIG. 23illustrates that the melt-bondable panel mounting bracket 108 e can alsoinclude one or more flow ways 168. The flow ways 168 can aid in forminga mechanical bond between the melt-bondable panel mounting bracket 108 aand a resin-based panel 102, as explained in greater detail above.

Additionally, in some implementations, the melt-bondable panel mountingbracket 108 e can include an attachment interface 194. The attachmentinterface 194 can allow a user to secure a rotational tool, or drillsocket, directly to the melt-bondable panel mounting bracket 108 e. Theattachment interface 194 can include any number of configurations thatallow for coupling to a rotational tool or drill socket. For example,FIG. 22 illustrates that the attachment interface 194 can have a hex-nutshape.

In some implementations, the attachment interface 194 can comprise a hexnut secured within female receptacle of the melt-bondable panel mountingbracket 108 e. In alternative implementations, the attachment interface194 can integrally formed into the body 160 of the melt-bondable panelmounting bracket 108 e. For example, a manufacturer can mill orotherwise form the attachment interface 194 into the body 160 of themelt-bondable panel mounting bracket 108 e.

As alluded to above, the melt-bondable panel mounting bracket 108 e canalso include an alignment stem 192. The alignment stem 192 can comprisea cylindrically-shaped column. In alternative implementations, thealignment stem 192 can comprise a rod or other configuration that allowsa user to insert the alignment stem 192 into a guide hole 190. To allowa user to insert the alignment stem 192 into the guide hole 190, thealignment stem 192 can extend farther from the melt-bondable panelmounting bracket 108 e that the bonding protrusion(s) 164. For example,the one or more bonding protrusions 164 can extend a first distance in adirection generally away from the body 160 of the melt-bondable panelmounting bracket 108 e. The alignment stem 192 can extend a seconddistance in a direction generally away from the body 160, the seconddistance being greater than the first distance.

Referring now to FIGS. 24 and 25, an implementation of a bracketmounting system 180 a is illustrated driving the melt-bondable panelmounting bracket 108 e directly into a panel 102. Unlike the bracketmounting system 108 of FIGS. 19-21 that includes three separatecomponents, the bracket mounting system 180 a is a single device. Asshown by FIGS. 24 and 25, the bracket mounting system 180 a can includea drill interface 202, a fender 210, and a stop guide 200. The drillinterface 202 can couple the melt-bondable panel mounting bracket 108 eto a rotation tool, such as a high-speed drill 196. For instance, FIG.24 illustrates that the drill interface 202 can comprise a socket 202.Thus, a user can secure a first end 203 of the drill interface directlyto a high-speed drill 196, and a second opposing end over the attachmentinterface 194 of the melt-bondable panel mounting bracket 108 e.

As shown in FIG. 24, the fender 210 can extend from the drill interface202. In addition to the fender 210 and the drill interface 202, thebracket mounting system 180 a can also include a stop guide 200. Thestop guide 200 can interface with the fender 210 to control the distancethe melt-bondable panel mounting bracket 108 e is inserted into thepanel 102. As shown in FIG. 24, the stop guide 200 can include an innerrecess 204 having a size and shape to allow a user to insert amelt-bondable panel mounting bracket 108 e therein.

In addition to the foregoing, the bracket mounting system 180 a caninclude one or more bearings 206 that allow the drill interface 202 andfender 210 to rotate relative to the stop guide 200. This can allow auser to hold the stop guide 200 while using the bracket mounting system180 a to secure the melt-bondable panel mounting bracket 108 e into thepanel 102. The bracket mounting system 180 a can also include a spring208 configured to bias the fender 210 away from the guide stop 200.

A user can secure a melt-bondable panel mounting bracket 108 e into apanel 102 using the bracket mounting system 180 a. For example, the usercan drill a guide hole 190 into a mounting surface 102 a of the panel102. As shown by FIGS. 24 and 25, the user can drill the guide hole 190only partially through the panel 102. One will appreciate that this canhelp conceal the melt-bondable panel mounting bracket 108 e.

At this point, or before if desired, the user can secure the drillinterface 202 to the attachment interface 194 of the melt-bondable panelmounting bracket 108 e. In particular, the user can insert themelt-bondable panel mounting bracket 108 e into the cavity 204 of thestop guide 204 until the attachment interface 194 engages the drillinterface 202. The user can then the position the guide stop 200 on thepanel 102 about the guide hole 190.

To help ensure that the melt-bondable panel mounting bracket 108 d isproperly aligned, the user can also insert an alignment stem 192 intothe guide hole 190. In order to insert the alignment stem 192 into theguide hole 190, the user can apply a downward force to the bracketmounting system 180, thereby partially compressing the spring 208. Withthe alignment stem 192 placed within the guide hole 190, the user canthen employ the high-speed drill 196 to rotate the melt-bondable panelmounting bracket 108 e into the panel 102. In particular, the user cansecure high-speed drill 196 to the first end 203 of the drill interface202. The user can then use the high-speed drill 196 to rotate themelt-bondable panel mounting bracket 108 e at a high rate of rotation.For example, the user can use the high-speed drill 196 to rotate themelt-bondable panel mounting bracket 108 e at between about 1700revolutions per minute and about 2200 revolutions per minute.

The user can hold the guide stop 200 to prevent it from rotating. Uponrotation, the user can apply moderate downward pressure to advance thebonding protrusion(s) 164 of the melt-bondable panel mounting bracket108 e into the panel 102. One will appreciate that the ridges 167 canfunction as threads and help advance the melt-bondable panel mountingbracket 108 e into the panel 102. The user can advance the melt-bondablepanel mounting bracket 108 e until the fender 210 comes into contactwith the guide stop 200. Specifically, the fender 210 and guide stop 200can prevent further advancement of the melt-bondable panel mountingbracket 108 e. One will appreciate in light of the disclosure hereinthat the guide stop 200 can have a size and configuration to prevent auser from advancing the melt-bondable panel mounting bracket 108 e toofar into the panel 102.

Implementations of the present invention also include methods ofassembling and securing resin-based panels a support structure as apartition, display, treatment, barrier, or other structure. Thefollowing describes at least one implementation of a method of mountingresin-based panels 102 to a support structure 156 with reference toFIGS. 1-25. Of course, as a preliminary matter, one of ordinary skill inthe art will recognize that the methods explained in detail can bemodified in a wide variety of ways to install a wide variety ofconfigurations using one or more components of the present invention. Inparticular, various acts of the method described below can be omitted orexpanded, and the order of the various acts of the method described canbe altered as desired. Thus, one should view the following acts or stepsas an example of one implementation of a method in accordance with thepresent invention.

For example, in at least one method of the present invention, a user cansecure at least one resin-based panel 102 to a support structure 156using one or more of the components described herein. Specifically, themethod can involve securing one of a locking pin 106 and a housing 104to a support structure. For example, a user can secure a locking pin 106to a support structure 156 using an anchor (not shown).

The method can additionally involve securing the other of the lockingpin and the housing to a panel. For example, a user can secure thehousing 104 to a resin-based panel 102 by inserting a male connector 146of a crown disk 114 through a perforation in the resin-based panel 102.The user can then secure a standoff cap to the end of the male connector104 until it rests against the display surface 102 b of the resin-basedpanel 102 a.

Alternatively, the method can involve heating a melt-bondable panelmounting bracket 108 to a temperature sufficient to at least partiallymelt the resin of a resin-based panel 102. Once the user has heatedmelt-bondable panel mounting bracket 108 to a sufficient temperature,the method can involve pressing the melt-bondable panel mounting bracket108 into a bonding surface 102 a of the resin-based panel 102. As a userpresses melt-bondable panel mounting bracket 108 into a resin-basedpanel 102, the melt-bondable panel mounting bracket 108 can cause atleast a portion of the resin of the resin-based panel 102 to at leastpartially melt. As the resin melts and softens it can begin to flow orbe displaced into and around the various bonding features of themelt-bondable panel mounting bracket 108, as explained in greater detailabove. Alternatively, pressing the melt-bondable panel mounting bracket108 into a bonding surface 102 a of the resin-based panel 102 caninvolve an automated machine, such as a computer numerical controlmachine (CNC machine), heating and pressing multiple melt-bondable panelmounting brackets 108 into a resin-based panel 102 simultaneously.

Alternatively, the method can involve drilling a guide hole 190 at leastpartially through a resin panel. The method can then include insertingan alignment stem 192 of a melt bondable mounting bracket 108 e into theguide hole 190. Thereafter the method can involve rotating themelt-bondable panel mounting bracket 108 e at a high rate of rotationthereby causing resin of the resin panel 102 to melt about one or moreridges 167 of the melt-bondable panel mounting bracket 108 e.Furthermore, the method can involve advancing the melt-bondable panelmounting bracket 102 e into the resin panel 102.

Once the user has permanently affixed the melt-bondable panel mountingbracket 108 within the resin-based panel 102, or even before if desired,the method can involve securing the housing 104 to the melt-bondablepanel mounting bracket 108. For example, the user can thread the maleconnector 146 of a crown disk 114 into a female receptacle 174 of themelt-bondable panel mounting bracket 108. In alternativeimplementations, in which a twist-lock mounting assembly 100 is notused, the method can involve securing a standoff barrel to themelt-bondable panel mounting bracket 108.

The method can further involve securing the locking pin 106 to thehousing 104. More specifically, the method can involve inserting thelocking pin into the housing, thereby causing the locking pin toautomatically rotate relative to the housing into a locked position,whereby the housing prevents the locking pin from being removed from thehouse. As described in greater detail above, as the user inserts thelocking pin 106 into the housing 104, locking pin 106 can automaticallyrotate relative to the housing 104 into a locked position.

Additionally, in some implementations, the method of the presentinvention can involve dismounting a resin-based panel 102 from a supportstructure. For example, the method can involve moving the locking pin106 toward the disk crown 114, thereby causing the locking pin 106 toengage a pair of helical protrusions 140. The pair of helicalprotrusions 140 can cause the locking pin 114 to rotate at leastpartially from the locked position toward the released position. Themethod can then involve retracting the locking pin 106 from the housing104. As the user pulls the locking pin 106 from the housing 104, thehousing 104 can cause the locking pin 106 to rotate into the releasedposition, thereby allowing the locking pin 106 to exit the housing 104.

As the forgoing methods illustrate, systems and components of thepresent invention provide a great deal of versatility in mountingpanels. In particular, the systems and components of the presentinvention enable panels to be secured to support structure using variouscomponents which allow for simple and fast assembly, protect the panelfrom damage, and provide a pleasing aesthetic.

The present invention may be embodied in other specific forms withoutdeparting from its spirit or essential characteristics. For example, thetwist-lock mounting assemblies have been described herein above asincluding a locking pin having a flange that engages features in ahousing that cause the locking pin to rotate in and out of locked andreleased position. In additional implementations, the housing caninclude one or more flanges that engage features on a locking pin thatcause the housing to rotate about the locking pin in and out of lockedand released positions.

The described embodiments are to be considered in all respects only asillustrative and not restrictive. The scope of the invention is,therefore, indicated by the appended claims rather than by the foregoingdescription. All changes that come within the meaning and range ofequivalency of the claims are to be embraced within their scope.

1. A melt-bondable panel mounting bracket for mounting an object, suchas a decorative architectural resin-based panel, to a support structurecomprising: a body; one or more bonding protrusions extending a firstdistance in a direction generally away from the body; one or more ridgesextending generally transversely from the one or more bondingprotrusions; and an alignment stem extending a second distance in adirection generally away from the body, the second distance beinggreater than the first distance.
 2. The bracket as recited in claim 1,further comprising: a bonding surface from which the one or more bondingprotrusions extend; and one or more recesses extending generally intothe bonding surface.
 3. The bracket as recited in claim 1, furthercomprising one or more flow recesses extending generally transverselyinto the one or more bonding protrusions.
 4. The bracket as recited inclaim 1, further comprising a connection member configured to connectthe melt-bondable panel mounting bracket to an additional hardwarecomponent.
 5. The bracket as recited in claim 4, further comprising aslot extending into the connection member, wherein the slot isconfigured to be placed about a standoff or screw.
 6. The bracket asrecited in claim 1, further comprising an attachment interfaceconfigured to be coupled to a rotation tool.
 7. The bracket as recitedin claim 5, wherein the attachment interface comprises a hex-nut shapedextension coupled to the body.
 8. The bracket as recited in claim 1,wherein the alignment stem comprising a cylindrically shaped column. 9.A system for securing a melt-bondable panel mounting bracket into aresin panel, comprising: a drill interface configured to couple amelt-bondable panel mounting bracket to a rotation tool; a fendercoupled to the drill interface; and a stop guide configured to receivethe melt-bondable panel mounting bracket therein; wherein the stop guideprevents advancement of the melt-bondable panel mounting bracket and thefender relative to the stop guide after the melt-bondable panel mountingbracket has been advanced a predetermined distance into the resin panel.10. The system as recited in claim 9, further comprising a springconfigured to bias the fender away from the stop guide.
 11. The systemas recited in claim 9, wherein the drill interface comprises a bithaving a first end configured to be received within a rotation tool, anda second end configured to receive an attachment interface of themelt-bondable panel mounting bracket.
 12. The system as recited in claim9, wherein the stop guide is configured to be rotationally fixed.
 13. Amethod of mounting a panel to a support structure, comprising: drillinga guide hole at least partially through a resin panel; inserting analignment stem of a melt bondable mounting bracket into the guide hole;rotating the melt-bondable panel mounting bracket at a high rate ofrotation thereby causing resin of the resin panel to melt about one ormore ridges of the melt-bondable panel mounting bracket and therebycreating a bond between the melt-bondable panel mounting bracket and theresin panel; and advancing the melt-bondable panel mounting bracket intothe resin panel.
 14. The method as recited in claim 13, furthercomprising securing a drill interface to the melt-bondable panelmounting bracket.
 15. The method as recited in claim 14, whereinsecuring a drill interface to the melt-bondable panel mounting bracketcomprises securing a hex nut within a connection o member of themelt-bondable panel mounting bracket.
 16. The method as recited in claim13, further comprising securing the melt-bondable panel mounting bracketto a support structure via a standoff.
 17. The method as recited inclaim 16, further comprising positioning the standoff within a slot ofthe connection member of the melt-bondable panel mounting bracket. 18.The method as recited in claim 16, further comprising: securing one of alocking pin and a housing to a support structure; securing the other ofthe locking pin and the housing to the melt-bondable panel mountingbracket; inserting the locking pin into the housing, wherein: thelocking pin automatically rotates relative to the housing into a lockedposition; and the housing prevents the locking pin from being removedfrom the housing.
 19. The method as recited in claim 13, furthercomprising rotating the melt-bondable panel mounting bracket at betweenabout 1700 revolutions per minute and about 2200 revolutions per minute.20. The method as recited in claim 13, further comprising advancing themelt-bondable panel mounting bracket into the resin panel until a fendercontacts a stop guide, thereby preventing further advancement of themelt-bondable panel mounting bracket into the resin panel.